Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/49—Phosphorus-containing compounds
  • C08K5/51—Phosphorus bound to oxygen
  • C08K5/52—Phosphorus bound to oxygen only
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/49—Phosphorus-containing compounds
  • C08K5/51—Phosphorus bound to oxygen
  • C08K5/52—Phosphorus bound to oxygen only
  • C08K5/5205—Salts of P-acids with N-bases
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/16—Nitrogen-containing compounds
  • C08K5/34—Heterocyclic compounds having nitrogen in the ring
  • C08K5/3412—Heterocyclic compounds having nitrogen in the ring having one nitrogen atom in the ring
  • C08K5/3432—Six-membered rings
  • C08K5/3435—Piperidines
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/16—Nitrogen-containing compounds
  • C08K5/34—Heterocyclic compounds having nitrogen in the ring
  • C08K5/3467—Heterocyclic compounds having nitrogen in the ring having more than two nitrogen atoms in the ring
  • C08K5/3477—Six-membered rings
  • C08K5/3492—Triazines
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
  • C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/16—Nitrogen-containing compounds
  • C08K5/34—Heterocyclic compounds having nitrogen in the ring

Definitions

• This invention relates to the process for the preparation of an amine salt stabilizer that is useful for improving the color and hydrolytic stability of a polymer composition
• a polymer composition comprising (A) at least one polyester prepared by the reaction of at least one diol with at least one dicarboxylic acid/or dialkyl ester thereof in the presence of a metallic catalyst; and optionally a polycarbonate.
• the stabilizer is a salt made by reacting an acidic phosphorus containing compound, preferably phosphorous acid, with at least one suitable hindered amine light stabilizer (HALS).
• HALS hindered amine light stabilizer
• phosphorus-containing compounds examples include phosphoric acid, certain organic phosphorus containing compounds such as distearylpentaerythritol diphosphite, mono-, di-, and trihydrogen phosphate compounds, or di- and triester phosphate compounds, phosphite compounds, certain inorganic phosphorus containing compounds such as monosodium phosphate, zinc or calcium phosphates, poly(ethylene)hydrogen phosphate, phosphites and phosphates used in combination with elementary sulfur, silyl phosphates, phosphorus containing compounds used in combinations with metal sulphides or metal sulphates.
• organic phosphorus containing compounds such as distearylpentaerythritol diphosphite, mono-, di-, and trihydrogen phosphate compounds, or di- and triester phosphate compounds
• phosphite compounds certain inorganic phosphorus containing compounds such as monosodium phosphate, zinc or calcium phosphates
• Patent 4,452,933 discloses the use of hydroxy- or amino-substituted carboxylic acids such as methyl salicylate, maleic acid, glycine, or dibutyl tartrate to inactivate metal catalyst residues.
• U.S. Patent 4,452,932 discloses the use of dehydroacetic acid and hydroxy-aromatic compounds such as o-hydroxybenzophenone for inactivating metal catalyst residues. It also is known that certain polyols such as mannitoi can be used to improve the color of polyester and polycarbonate blends as described in European Patent 0272417 (Nelson).
• U.S. Patent 4,619,956 discloses the combination of 2,2,6,6-tetraalkyl- piperidine hindered amine light stabilizers (HALS) and/or their addition salts with triazine ultraviolet absorbers for stabilizing thermoset acrylic and alkyd coatings.
• HALS hindered amine light stabilizers
• U.S. Patent 5,714,530 discloses the utility of combining non-polymeric 2,2,6,6,-tetraalkyl- piperidine HALS salts and/or their acid addition salts with triazine ultraviolet light absorbers for stabilizing certain polymer compositions.
• Patent 6,051 ,164 discloses the use of a polymer stabilizing system comprising from about 50 to about 5,000 ppm of at least one ortho hydroxyl tris-aryl triazine light absorber and from about 500 ppm to about 1.25 percent of at least one oligomeric, polymeric or high molecular weight HALS having a molecular weight of at least about 500, wherein the weight ratio of HALS to triazine light absorber is from about 3:1 to about 20:1.
• Certain of these phosphorus-containing compounds e.g., phosphoric acid, phosphorous acid, and polyphosphoric acid, can react with processing equipment to produce a dark colored polymer and can lead to the formation of black specks or particles.
• the dark color is the due to corrosion of the process equipment.
• Addition of strong acids to the polymer compositions also reduces the hydrolytic stability as a result of acid catalyzed hydrolysis.
• phosphite antioxidants can be hydrolyzed to acidic species thereby corroding process equipment or reducing the hydrolytic stability of the polymer composition. It is desirable to provide an additive or mixture of additives that can be used to deactivate metal catalyst residues and other metal impurities and thereby improve the color of polyester-polycarbonate compositions, lead to less corrosion of process equipment, and suppress transesterification.
• a synthetic process has been discovered for making certain salts of hindered amine light stabilizers (HALS) that are useful stabilizers in polyesters, polycarbonates and blends of polyesters and polycarbonates.
• HALS hindered amine light stabilizers
• the use of these salts results in polymer compositions that exhibit improved hydrolytic stability, that are less detrimental to process equipment, that provide better color, and that provide less batch-to-batch variation in color.
• the salts useful in the present invention are reaction products of a suitable inorganic acid, such as a phosphorous acid, with a HALS.
• This invention relates to a process for the preparation of an addition salt of at least one hindered amine light stabilizer and at least one acidic phosphorus containing compound comprising the step of combining at least one hindered amine light stabilizer and at least one acidic phosphorus containing compound so that the addition salt is formed.
• Another aspect of the invention is a process for the preparation of an addition salt of at least one hindered amine light stabilizer and at least one acidic phosphorus containing compound
• at least one acidic phosphorous compound (component A) is selected from phosphorous acid, phosphoric acid, and polyphosphoric acid and is dissolved in at least one polar solvent (I) wherein polar solvent (I) is selected from methanol, ethanol, n-propanol, isopropanol, n-butanol and isobutanol
• polar solvent (I) is selected from methanol, ethanol, n-propanol, isopropanol, n-butanol and isobutanol
• at least one hindered amine light stabilizer (component B) is dissolved in at least one aromatic hydrocarbon solvent (II) selected from toluene, xylene, and benzene
• Step 3) components (A) and (B) are subsequently mixed to form a
• Yet another a spect of the invention i s a process for the preparation of a n addition salt of at least one h indered amine light stabilizer a nd at least one acidic phosphorus containing compound wherein the acidic phosphorus containing compound and the hindered amine light stabilizer are mixed, ground, and/or pulverized and subsequently melt blended into a polymer vehicle at a level of up to about 10 weight percent based upon the polymer.
• the preferred polymers are polyesters and polycarbonates. Polyesters are more preferable.
• a process for the preparation of an addition salt of at least one hindered amine light stabilizer and at least one acidic phosphorus containing compound comprising the following steps:
• Step 1 component (A) is dissolved in a polar solvent (I) and component (B) is dissolved in a non-polar aliphatic hydrocarbon solvent (III) which is immiscible with polar solvent (I);
• Step 2 components (A) and (B) are mixed to form a biphasic mixture wherein the addition salt migrates to the polar solvent phase; and
• Step 3 feeding the polar phase of step 2 to a vessel containing the nonpolar phase of step 2 and vaporizing polar solvent (I) as the polar phase of step 2 is added to the vessel of step 3 to produce a slurry of the salt in the nonpolar aliphatic hydrocarbon solvent
• a process for the preparation of an addition salt of at least one hindered amine light stabilizer and at least one acidic phosphorus containing compound comprising the following steps:
• Step 1 component (A) and component (B) are mixed in a polar solvent with stirring until a homogeneous solution is obtained;
• Step 2 the solution of step 1 is fed to a spray dryer and the solid product is isolated by spray drying.
• the present invention demonstrates the use of an additive that improves the hydrolytic stability of polyesters, polycarbonates, and polyester-polycarbonate blends and provides improved color to polyesters and polyester-polycarbonate blends.
• the present invention provides a process for the preparation of an addition salt of at least one hindered amine light stabilizer and at least one acidic phosphorus containing compound comprising the step of combining the following:
• Component A At least one acidic phosphorus containing compound referred to herein as "Component A” selected from compounds having the formulas:
• Ri and R 2 are independently selected from hydrogen, d-C 2 2-alkyl, substituted C ⁇ -C 22 -alkyl, C 3 -C 8 -cycIoalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, and aryl; n is 2 to 500; and (B) at least one hindered amine light stabilizers (HALS), referred to herein as "Component B", selected from compounds having the formulas:
• Ra, R 4 , R5, and Re are independently selected from hydrogen, C ⁇ -C 2 2-alkyl, substituted C 1 -C 22 -alkyl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, aryl;
• R 7 is selected from hydrogen, -OR 6 , CrC 2 -alkyl, substituted C ⁇ -C 22 -alkyl, C 3 -Ca-cycloalkyl, substituted C 3 -C ⁇ -cycloalkyl;
• R 8 is selected from hydrogen; CrC 22 -alkyl, substituted C ⁇ -C2 2 -alkyl, C 3 -C 8 - cycloalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, aryl, -Y R ⁇ or a succinimido group having the formula
• R 9 and R-io are independently selected from hydrogen, C ⁇ -C 22 -alkyl, substituted C ⁇ -C 22 -alkyl, C 3 -C 8 -cycloalkyl, and substituted C 3 -C 8 -cycloalkyl;
• Rg and Rio may collectively represent a divalent group forming a ring with the nitrogen atom to which they are attached, e.g., morpholino, piperidino and the like;
• Li is a divalent linking group selected from C 2 -C 2 2-alkylene; -(CH 2 CH 2 -Y ⁇ ) ⁇ - 3 - CH 2 CH -; C 3 -C 8 -cycloalkylene; arylene; or -CO-L2-OC-;
• L 2 is selected from C ⁇ -C 2 2-alkylene, arylene, -(CH2CH2-Y ⁇ ) ⁇ - 3 -CH 2 CH 2 - and C 3 - C 8 -cycloalkylene; Yi is selected from -OC(O)-, -NHC(O)-, -O-, -S-, -N(Ri)-;
• Y is selected from -O- or -N(R- ⁇ )-;
• Z is a positive integer of up to about 20, preferably up to about 6; mi, is selected from 0 to about 10; n1 is a positive integer selected from 2 to about 12;
• R ⁇ , and R 12 are independently selected from hydrogen, C C22-al yl, substituted C ⁇ -C 2 -alkyl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, aryl, and radical A wherein radical A is selected from the following structures:
• R-n and R 12 is an A radical; and wherein the ratio of the number of phosphorus atoms in the acidic phosphorus-containing compound to the number of basic nitrogen atoms in the HALS is about 0.25 to about 2, preferably from about 0.5 to about 1.1.
• the ratio of the number of phosphorus atoms in the acidic phosphorus containing compound to the number of basic nitrogen atoms (sp 3 hybridized) in the HALS is about 0.25 to about 2, preferably from about 0.5 to about 1.1. Additionally, the most preferred phosphorus containing compound is phosphorous acid.
• Method A - The first preferred method is to: (Step 1) dissolve at least one acidic phosphorus containing compound (Component A) in a polar solvent (I); (Step 2) dissolve at least one hindered amine light stabilizer (Component B) in an aromatic hydrocarbon solvent (II), and, subsequently, (Step 3) to mix Components (A) and (B) to form a homogenous solution of the addition salt.
• Step 4 the homogeneous solution of step 3 is mixed with a nonpolar aliphatic hydrocarbon solvent (III) at a rate such that the addition salt precipitates.
• polar solvent i.e., aromatic hydrocarbon solvent (II), and nonpolar aliphatic hydrocarbon solvent (III) are the same throughout this description for all embodiments.
• polar means the solvent is comprised of molecules that exhibit properties consistent with a permanent, moderate to high dipole moment and possess a moderate to high dielectric constant.
• non-polar solvent comprises molecules that do not exhibit or have a low dipole moment, and have a low dielectric constant.
• a solvent exhibiting a dielectric constant of greater than 3 is considered to be polar.
• polar solvent (I) non-limiting examples of polar or moderately polar solvents which are intended to be covered by the current process include, alcohols, diols, esters, nitriles, and mixtures thereof.
• the solvent is an alcohol.
• Polar solvents within this invention preferably have dielectric constants greater than 3, more preferably greater than 10, and more preferably greater than 18. More preferably, the solvent is isopropanol, ethanol or methanol. Even more preferably, the preferred solvents are methanol and isopropanol, and most preferably, methanol. It is preferred that the acidic phosphorus containing compound be present in a polar solvent (I) in the amount of 0.1 to 50 weight percent, preferably 25 to 35 weight percent for Methods A and C.
• a polar solvent (I) in the amount of 0.1 to 50 weight percent, preferably 25 to 35 weight percent for Methods A and C.
• aromatic hydrocarbon solvents (II) any aromatic hydrocarbon solvent known in the art may be useful.
• HALS be present in aromatic hydrocarbon solvents (II) in the amount of 0.1 to 45 weight percent, preferably 10 to 30 weight percent.
• the HALS be present in the aromatic hydrocarbon solvent (II) in a ratio by weight of HALS to aromatic hydrocarbon solvent of 1:2 to 1:20, preferably 1 :2.5 to about 1 :10 and all fractions within these ranges.
• any nonpolar aliphatic hydrocarbon solvents known in the art may be useful. However, non-limiting examples are pentane, heptane, hexane, octane, isooctane, cyclobutane, cyclopentane, cyclohexane, and 1,3-dimethylcyclohexane.
• More preferred solvents of this type are heptane, hexane, and octane, but more preferably, heptane.
• the weight ratio of the polar solvent(s) (I) to the aromatic hydrocarbon solvents (II) be 0.075 to 1 and all fractions within this range.
• the total weight percentage of the salt formed be 0.1 to 40 weight percent based on the total combined weight of the polar solvent(s) (I), the aromatic hydrocarbon solvent(s) (II) and the nonpolar hydrocarbon solvent (111). It is more preferred in Method A that the total weight percentage of the salt formed be in the range of 5 to 15 weight percent based on the total combined weight of the polar solvent(s) (I), the aromatic hydrocarbon solvent(s) (II) and the nonpolar hydrocarbon solvent (III). All fractions within these ranges are within the scope of the present invention.
• Method B The second process embodiment relates to a process for reparation of an addition salt of Components A and B comprising the step of mixing, grinding and/or pulverizing, and subsequently melt extruding, Components A and B with a suitable polymer.
• Any mixing, grinding and/or pulverizing means known in the art may be used, including but not limited to, use of ball mills. Also, any melt extrusion method known in the art may be used.
• Suitable polymers include but are not limited to polyesters and polycarbonates wherein polyesters are preferred.
• Method C - The third process embodiment relates to a process for preparation of an addition salt of at least one HALS and at least one acidic phosphorus containing compound comprising the following steps:
• Step 1 component (A) is dissolved in a polar solvent (IV) and component (B) is dissolved in a non-polar aliphatic hydrocarbon solvent (III) which is immiscible with polar solvent (IV);
• Step 2 components (A) and (B) are mixed to form a biphasic mixture wherein the addition salt migrates to the polar solvent phase; and
• Step 3 feeding the polar phase of step 2 to a vessel containing the nonpolar phase of step 2 and vaporizing polar solvent (IV) as the polar phase of step 2 is added to the vessel of step 3 to produce a slurry of the salt in the nonpolar aliphatic hydrocarbon solvent (III); wherein Components (A) and (B) are the same as for Method A; and polar solvent (IV) as well as nonpolar aliphatic hydrocarbon solvent (III) are the same as for Method A including all preferred embodiments.
• a heterogeneous solution is obtained by mixing two solutions comprising: Component (A), the acidic phosphorus containing compound dissolved in polar solvent (IV); and Component (B), the HALS, dissolved into in a nonpolar aliphatic hydrocarbon solvent (III); wherein the addition salt migrates into the polar solvent (IV) as two distinct phases form and the nonpolar aliphatic hydrocarbon solvent (III) is transferred to a vessel and agitated wherein the vessel is heated under reduced pressure such that the polar solvent (IV) can be removed by distillation or other evaporation techniques at an approximate addition rate wherein the addition salt is precipitated.
• the polar solvent phase of step (B) comprises a ratio of polar solvent (IV) to nonpolar aliphatic hydrocarbon solvent (III) of 1:20 to about 2:1. It is preferred that the at least one nonpolar aliphatic hydrocarbon solvent (III) are added so that the total weight percent of the salt in the total solvent mixture of step (C) of Method C is less than 30 weight percent. All fractions within the stated ranges are within the scope of the present invention.
• polar solvent (IV) non-limiting examples of polar or moderately polar solvents which are intended to be covered by the current process include, water, alcohols, diols, esters, nitriles, and mixtures thereof.
• the solvent is an alcohol and water.
• Polar solvents within this invention preferably have dielectric constants greater than 3, more preferably greater than 10, and more preferably greater than 18. More preferably, the solvent is isopropanol, ethanol or
• the preferred solvents are methanol and isopropanol, and most preferably, methanol. It is preferred that the acidic phosphorus containing compound be present in a polar solvent (IV) in the amount of 0.1 to 50 weight percent, preferably 25 to 35 weight percent for Methods A and C.
• Method D - The fourth process embodiment relates to a process for preparation of an addition salt of Components A and B comprising the following steps:
• Step 1 mixing Components A and B in polar solvent (IV) until a homogeneous solution is obtained;
• Step 2 Isolation of the acid addition salt by spray drying.
• Examples of preferred solvents to be used in Method D include but are not limited to water, methanol, isopropanol and ethanol.
• Method D it is preferred for Method D that the HALS and acidic phosphorus containing compound be present in the polar solvent in the amount of 0.1 to about 40 weight percent, preferably 10 to 30 weight percent and all fractions within these ranges.
• the ratio of the number of phosphorus atoms in the acidic phosphorus containing compound to the number of basic nitrogen atoms in the HALS be from about 0.2 to about 1.1, preferably from about 0.4 to about 1.0 and all fractions within these ranges.
• the acidic phosphorus containing compound is selected from phosphorous acid, phosphoric acid and polyphosphoric acid wherein phosphorous acid is the most preferable.
• spray drying is defined as rapid evaporation, in which a solution is heated so that the dissolved substance falls out of the spray in the solid state.
• the process of spray drying is well understood by one skilled in the art.
• C C 22 -alkyl denotes a saturated hydrocarbon radical which contains one to twenty-two carbons and which may be straight or branched-chain.
• Such C 1 -C 2 2 alkyl groups can be methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, isopropyl, isobutyl, tertbutyl, neopentyl, 2-ethylheptyl, 2-ethylhexyl, and the like.
• substituted C ⁇ -C 22 -alkyl refers to C ⁇ -C 22 -alkyl radicals as described above which may be substituted with one or more substituents selected from hydroxy, halogen, cyano, aryl, heteroaryl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, C ⁇ -C 6 -alkoxy, C 2 -C 6 alkanoyloxy and the like.
• C 3 -C 8 -cycloalkyl is used to denote a cycloaliphatic hydrocarbon radical containing three to eight carbon atoms.
• substituted C 3 -C 8 - cycloalkyl is used to describe a C 3 -C 8 -cycloalkyl radical as detailed above containing at least one group selected from C ⁇ -C 6 -alkyl, C ⁇ -C 6 -alkoxy, hydroxy, halogen, and the like.
• aryl is used to denote an aromatic radical containing 6,10 or 14 carbon atoms in the conjugated aromatic ring structure and these radicals substituted with one or more groups selected from GrC ⁇ -alkyl; C ⁇ -C 6 -alkoxy; phenyl, and phenyl substituted with Ci-C ⁇ -alkyl; C ⁇ -C 6 -alkoxy; halogen and the like; C 3 -C 8 -cycloalkyl; halogen; hydroxy, cyano, trifluoromethyl and the like.
• Typical aryl groups include phenyl, naphthyl, phenylnaphthyl, anthryl (anthracenyl) and the like.
• heteroaryl is used to describe conjugated cyclic radicals containing at least one hetero atom selected from sulfur, oxygen, nitrogen or a combination of these in combination with from two to about ten carbon atoms and these heteroaryl radicals substituted with the groups mentioned above as possible substituents on the aryl radical.
• Typical heteroaryl radicals include: 2-and 3-furyl, 2- and 3-thienyl, 2- and 3- pyrrolyl, 2-, 3-, and 4-pyridyl, benzothiophen-2-yl; benzothiazol-2-yl, benzoxazol-2-yl, benzimidazol-2-yl, 1, 3, 4-oxadiazol-2-yl, 1 , 3, 4-thiadiazol-2-yl, 1 ,2,4-thiadiazol-5-yl, isothiazol-5-yl, imidazol-2-yl, quinolyl and the like.
• CrCe-alkoxy and "C 2 -C 6 -aIkanoyloxy” are used to represent the groups -O-C ⁇ -C 6 -alkyl and -OCOCrC 6 -alkyl, respectively, wherein “C ⁇ -C 6 -alkyr denotes a saturated hydrocarbon that contains 1-6 carbon atoms, which may be straight or branched-chain, and which may be further substituted with one or more groups selected from halogen, methoxy, ethoxy, phenyl, hydroxy, acetyloxy and propionyloxy.
• halogen is used to represent fluorine, chlorine, bromine, and iodine; however, chlorine and bromine are preferred.
• C 2 -C 22 -alkylene is used to denote a divalent hydrocarbon radical that contains from two to twenty-two carbons and which may be straight or branched chain and which may be substituted with one or more substituents selected from hydroxy, halogen, Ci-C ⁇ -alkoxy, C2-C6-alkanolyloxy and aryl.
• C 3 -C 8 - cycloalkylene is used to denote divalent cycloaliphatic radicals containing three to eight carbon atoms and these are optionally substituted with one or more CrC ⁇ -alkyl groups.
• arylene is used to denote 1,2-, 1 ,3-, and 1 ,4-phenylene radicals and these optionally substituted with C ⁇ -C 6 - alkyl, CrC 6 -alkoxy and halogen.
• the acidic phosphorus-containing compounds in all embodiments of the invention preferably are phosphorous acid, phosphoric acid and polyphosphoric acid, most preferably phosphorous acid.
• HALS examples include: Cyasorb UV-3346 (Cytec Industries, CAS# 90751-07-8), Cyasorb UV-3529 (Cytec Industries, CAS# 219920-30-6), Cyasorb UV-3641 (Cytec Industries, CAS# 106917- 30-0), Cyasorb UV-3581 (Cytec Industries, CAS# 79720-19-7), Cyasorb UV-3853 (Cytec Industries, CAS# 167078-06-0), Cyasorb UV-3853S (Cytec Industries, CAS# 24860-22-8), Tinuvin 622 (Ciba Specialty Chemicals, CAS# 65447-77-0), Tinuvin 770 (Ciba Specialty Chemicals, CAS# 52829-07-9), Tinuvin 144 (Ciba Specialty Chemicals, CAS# 63843-89-0), Tinuvin 123 (Ciba Specialty Chemicals, CAS# 129757-
• the hindered amine light stabilizers having above formulas (3)-(13) are preferred.
• Chimassorb 944 (Ciba Specialty Chemicals, CAS# 71878-19-8), Cyasorb UV-3529 (Cytec Industries, CAS# 219920- 30-6), Chimassorb 119 (Ciba Specialty Chemicals, CAS# 106990-43-6) and Tinuvin 770 (Ciba Specialty Chemicals, CAS# 52829-07-9) and any equivalents thereof are specific examples of the preferred HALS.
• HALS high molecular weight HALS wherein the molecular weight is greater than about 1000 such as Cyasorb UV-3529 (Cytec Industries, CAS# 219920-30-6).
• polyester-polycarbonate compositions were made by extruding a 50/50 by weight blend of (1) a polyester comprised of 74 mole percent terephthalic acid residues, 26 mole percent ethylene glycol residues and 100 mole percent 1,4-cyclohexanedimethanol residues having an inherent viscosity of about 0.74 and containing approximately 100 ppmw titanium, (2) a bisphenol A polycarbonate supplied by Bayer as Makrolon 2608 polycarbonate and (3) the additive noted using an 18 mm twin-screw extruder (APV Chemical Machinery Inc., Saginaw, Ml 48601) equipped with a medium mixing screw. All zone temperatures were set to 275°C except for Zone 1 that was set at 250°C.
• the inlet port was cooled by circulating water and the screw speed was set to 200 revolution per minute (rpm).
• An Accu-Rate (ACCU-RATE Inc. Whitewater, Wl) dry material feeder was used to feed the polymers and additives into the extruder at a set addition rate of 3.0.
• the extruded rods were cooled by passing through a 1.37 meter (4.5 feet) long ice-water bath then chopped using a Berlyn pelletizer (The Berlyn Corp., Worcester, MA) set at a speed of 5-8. All additives were mixed with the polyester and polycarbonate by "bag blending" (shaking the materials together in a bag) unless otherwise stated.
• the polyester was dried for approximately 24 hours in a vacuum oven (Model 5851, National Appliance Company, Portland, OR) at 70°C at 120 Torr pressure with a slight ingress of dry nitrogen.
• the polycarbonate was dried for approximately 24 hours in a vacuum oven (Model 5840, National Appliance Company, Portland, OR) at 100°C at 120 Torr with a slight ingress of dry nitrogen.
• Concentrates were prepared from the blend of polymers and the additives and then dried under the same conditions as the polyester was dried. All of the polymers were stored in a vacuum oven under nitrogen until about 5 minutes prior to use, then "bag blended" and added to the feeder. The first 5 minutes of extrudate was not collected in order to ensure the extruder had been adequately purged.
• the instrument should be run according to its instructions using the following testing parameters: D65 Light Source (daylight, 6500°K color temperature), Reflectance Mode, Large Area View, Specular Included, CIE 10° Observer, Outputs are CIE L*, a*, b*.
• the pellets were placed in a holder that is 25 mm deep by 55 mm wide and high. The holder was black with a window on one side. During testing, the clear side of the holder was held at the reflectance port of the colorimeter as is normally done when testing in reflectance mode. An increase in the positive b* value indicates yellowness, while a decrease in the numerical value of b* indicates a reduction in yellowness.
• Polyester Method Ten mg of sample was added to a 10 mL volumetric flask followed by 20 microliters of toluene (as a flow marker) then diluted to a volume of 10 mL with an azeotrope of methylene chloride and hexafluoroisopropanol. A stir bar was added and the mixture was stirred on a stir plate until completely dissolved. The sample was analyzed using a Perkin-Elmer series 200 LC binary pump at a flow rate of 1.0 mL/minute., with a Perkin-Elmer ISS 200 Autosampler using a 10 microliter injection loop. The detector was a Perkin-Elmer LC-95 UV ⁇ is detector set at 285 nm.
• the columns are Plgel 5 micron guard and a Mixed C from Polymer Laboratories.
• the polystyrene calibration consists of 15 narrow molecular weight polystyrene standards from Polymer Laboratories ranging from 162 to 3,220,000.
• the universal calibration parameters were determined by linear regression to yield the correct weight average molecular weight for a set of five PCT samples previously characterized by light scattering.
• Polycarbonate Method The sample was pressed until it turned white to increase the surface area and then allowed to soak in tetrahydrofuran (THF) solvent to leach out the polycarbonate from the sample. Ten mg of sample was added to a 10 mL volumetric flask followed by 20 microliters of toluene (as a flow marker) then diluted to a volume of 10 mL with unstabilized THF. A stir bar was added and the mixture was stirred on a stir plate overnight. The sample was analyzed using a Perkin-Elmer LC 250 binary pump at a flow rate of 1.0 mL/min., with a Perkin-Elmer LC 600 Autosampler using a 20 microliter injection loop.
• THF tetrahydrofuran
• the detector was a Perkin- Elmer LC-235 photodiode array detector set at 265 nm.
• the columns were Plgel 5 micron guard, a Mixed C from Polymer Laboratories and an Oligopore column from Polymer Laboratories.
• the polystyrene calibration consisted of 15 narrow molecular weight polystyrene standards from Polymer Laboratories ranging from 162 to 3,220,000.
• the universal calibration parameters for polycarbonate in THF were obtained from the literature.
• Table I shows the b* value as measured on pellets extruded from the 50/50 by weight blend of polyester and polycarbonate containing various concentrations of Chimassorb 944, phosphorous acid, and water. Salts made from Chimassorb 944 and phosphorous acid may have varying ratios of phosphorous acid to Chimassorb 944 to improve the catalyst deactivation ability and improve the color of polyester-polycarbonate compositions.
• the amounts of Chimassorb 944 and phosphorous acid are given in grams and the amount of water is given in milligrams.
• a salt comprising about 0.02 to 0.3 weight percent phosphorous acid and 0.05 to about 0.5 weight percent Chimassorb 944 provided a suitable reduction in the pellet b* color without significantly reducing the polycarbonate molecular weight.
• Addition of low levels of water (Examples 9-12), from about 30 ppm to about 300 ppm, provided a further reduction in pellet b* color without having a significant impact on the polycarbonate molecular weight.
• Maintenance of the polycarbonate molecular weight (Mw) demonstrates that catalyst residues have been sufficiently deactivated.
• the slurry was heated to 60°C and stirred until a homogeneous solution was obtained.
• Isopropyl alcohol (370 g) was added to the reaction vessel.
• a solution of 115.46 g (1.41 mol) of phosphorous acid dissolved into 370 g of isopropyl alcohol was added slowly over approximately 1 hour.
• a homogeneous solution was obtained.
• the reaction mixture was pumped into an 18 L reaction vessel that contained rapidly stirred heptane (6840 g) over a period of approximately 1 hour.
• the resulting slurry was stirred for 30 minutes.
• the precipitate was collected by suction filtration.
• the filter cake was washed twice with 137 g of heptane then sucked dry on the filter paper overnight.
• the solid was placed in a 30.5 cm x 15.2 x 5.1 (12 inch x 6 inch x 2 inch) metal pan and dried in a vacuum oven at 50-60°C with a slight ingress of dry nitrogen until a constant mass was obtained.
• the dry product (Salt 1) weighed approximately 525 g (100% of theory).
• the feed rate of the reaction mixture into the heptane drowning vessel has some affect on the particle size of the final product. Slow feeds tend to produce a finer powder while higher feed rates will results in a larger particle that almost appears to be agglomerated. This needs to be balanced by the tendency for the salt to get sticky in the drowning vessel if the feed rate is too rapid. Typical bulk density of the dry salt has been between 0.4 and 0.6 g/ml.
• Cyasorb UV-3529 (82 g, 0.14 mole) was added and warmed to 40-50°C to effect solution.
• the phosphorous acid/methanol solution was added to the reaction vessel (exothermic reaction) with agitation and a small amount of cooling to maintain the temperature at 40-50°C over 15 minutes. A separated layer appears fairly quickly and after all of the acid solution was added, two distinct layers were present.
• the temperature of the flask was adjusted to 55°C (reflux will commence at about 57°C) and held for about an hour in insure complete reaction and uniform salt formation. Agitation was stopped and the two layers were allowed to separate. The temperature was held at 45-50°C. A slight amount of white solid appeared to be suspended in the upper heptane layer but eventually settled at the interface. The salt was dissolved in the lower methanol layer.
• a second 500 ml flask was equipped with thermometer, agitator, feed pump, distillation column, liquid/vapor separator configured to return the liquid reflux to the flask, cooled Dean Stark trap and receiver, and condenser.
• the flask was charged with heptane, 250 ml.
• the pressure was reduced to 290-300 mm of Hg and the temperature was raised to affect reflux, 60-62°C, both pot and vapor temperature.
• the bottom layer from the first reactor flask was pumped to the refluxing heptane at about 1-2 ml/min. The salt precipitated almost immediately and methanol appeared in the Dean Stark trap and separates as the lower layer.
• the vapor temperature dropped 5-10°C depending on the feed rate and amount of column packing used.
• the feed rate was adjusted to balance the rate of methanol being taken off. If the feed rate exceeds the rate of methanol take off, the salt may stick together. As long as most of the methanol was removed as it was being fed, the salt remained as a discrete solid that was easily maintained as a slurry. If stickiness is observed the feed can be stopped and the system will purge the excess methanol from the pot and discrete salt may be formed.
• the methanol/heptane azeotrope boiling point is 59°C at atmospheric pressure and is 52% methanol. At 406 mm the boiling point is 44°C and about the same composition.
• the feed nozzle for the methanol/salt solution was best located above the liquid, away from the sides of the flask. If the solution was allowed to drip on the cooler walls of the flask it tended to stick and become a solid mass.
• the reflux return from the condenser and Dean Stark trap should be returned to the flask so that the solution does not run down the sides of the flask for the same reason. Cool spots in the flask may promote sticking of the salt as a solid mass. The reflux could be returned subsurface.
• the feed rate of the methanol/salt solution had an affect the particle size of the final product. Slow feeds tended to produce a finer powder while higher feed rates resulted in a larger particle that almost appears to be agglomerated. The feed rates need to be balanced by the tendency for the salt to get sticky in the heptane. Typical bulk density of the dry salt was between 0.4 and 0.6 g/ml. [0064] The heptane remaining in the reactor flask can be used for the preparation of the next batch.

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